1. IMS 2020 Intelligent Manufacturing Systems Intelligent Manufacturing Systems Sustainable manufacturing Dimitris Kiritsis

2. IMS 2020 Intelligent Manufacturing Systems Supporting Global Research for IMS2020 Vision What is “Manufacturing” ? “Manufacturing covers the ‘Man-Industry Value Chain’, responding to human needs by the provision of products, processes and services. In broad terms, manufacturing is ‘the general trans-formation of all resources to meet human needs’ and this is why a smooth relationship must exist between supply and demand.” [Source: MANUFUTURE] 2

3. IMS 2020 Intelligent Manufacturing Systems Supporting Global Research for IMS2020 Vision What is “Sustainability” ? Sustainable development – “the development that meets the needs of the present without compromising the ability of future generations to meet their own needs” [Brundtland Commission, 1987] Sustainability is a quality that permits to preserve, to keep, to maintain.... – traditionally defined with three dimensions: environmental, social, and economical, while a forth one, technology, should be added as fundamental 3

4. IMS 2020 Intelligent Manufacturing Systems Supporting Global Research for IMS2020 Vision 4

5. IMS 2020 Intelligent Manufacturing Systems Supporting Global Research for IMS2020 Vision … in the context of sustainable engineering means: – to apply scientific knowledge to the design and implementation of materials, structures, product, systems, processes, etc. that take into account constrains coming from the 4 pillars of sustainability – to develop solutions for the design, operational and organizational activities related to products, processes and services in the manufacturing sector 5

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7. IMS 2020 Intelligent Manufacturing Systems Supporting Global Research for IMS2020 Vision Sustainable Manufacturing is defined in the last draft of the IMS MTP initiative as follows: “Sustainable manufacturing is a platform for development of innovative manufacturing technologies which address world wide resources shortages and excess environmental load to enable an environmentally benign life cycle.” 7

8. IMS 2020 Intelligent Manufacturing Systems Supporting Global Research for IMS2020 Vision Performance, Quality and Safety Natural resources and Environment Lifecycle aspects 8

9. IMS 2020 Intelligent Manufacturing Systems Supporting Global Research for IMS2020 Vision Manufacturing must be sustainable in terms of: – Performance (resource efficiency, energy efficiency, pollution reduction, …) of Products and Processes – Quality of products (including services) and processes – Safety of people (workers and other people affected in one or another way by manufacturing processes or facilities and their products), facilities and infrastructure Maintenance of manufacturing facilities is important to sustain: – (i) the performance of product and processes – (ii) the quality of processes – (iii) safety during product use and process operation 9

10. IMS 2020 Intelligent Manufacturing Systems Supporting Global Research for IMS2020 Vision Manufacturing should: Address world wide resources shortages and excess environmental load to enable an environmentally compatible life-cycle. Achieve minimum energy and material consumption in manufacturing as well as over the entire life-cycle of products and services. 10

11. IMS 2020 Intelligent Manufacturing Systems Supporting Global Research for IMS2020 Vision Sustainability of manufacturing is more and more affected by life-cycle considerations: - from design, - procurement & production, - transportation & setting up operation, - use, maintenance and - retirement & end of life of products. Additionally, this happens at global level and so requires the consideration of related technical, operational, societal and cultural issues (mindset). 11

12. IMS 2020 Intelligent Manufacturing Systems Supporting Global Research for IMS2020 Vision Design of eco products Sustainability as a requirement for new product development New materials and manufacturing techniques Resource & Energy efficient manufacturing Clean Technologies Information systems for product lifecycle management Closing the product information loops Involve the "consumer/user" in the lifecycle value chain Safety and risk management Education at all levels & changing mindsets 12

13. IMS 2020 Intelligent Manufacturing Systems Supporting Global Research for IMS2020 Vision Best practices for sustainable manufacturing: – Design of sustainable products – Design of sustainable processes – Design of sustainable services Interdisciplinary approach for the social dimension & mindset changing Global sustainable manufacturing roadmap Suggestions for research programs 13

14. IMS 2020 Intelligent Manufacturing Systems Supporting Global Research for IMS2020 Vision

15. IMS 2020 Intelligent Manufacturing Systems Supporting Global Research for IMS2020 Vision Intelligent products – based on embedded devices, allowing innovative operation, use and service models for improving product sustainability by extending their life and by reducing the use of resources and the impact on the environment New materials – for the design of lighter products, allowing easiness of disassembly/recovery/recycling, with lower impact on the environment 15

16. IMS 2020 Intelligent Manufacturing Systems Supporting Global Research for IMS2020 Vision Recycling technologies – Including Remanufacturing Real-World Manufacturing - Minimal Manufacturing Integrate Environmental Factors in Supply Chain optimisations – Consider SME needs – Avoid sub-optimisations 16

17. IMS 2020 Intelligent Manufacturing Systems Supporting Global Research for IMS2020 Vision Zero defect & zero pollution – Consider non-manufacturing elements Intelligent processes – Self adapting clean and safe micro-processes Combine Disciplines – Mechanical – Electronics – Chemical – Biology ECO-FACTORY 17

18. IMS 2020 Intelligent Manufacturing Systems Supporting Global Research for IMS2020 Vision Sustainable LCA Corporate social responsability Eco-social aspects – socio-laboral – health – discrimination – child labor High-tech Engineering Asset Management – Maintenance - Critical function for safety – No-disposal 18

19. IMS 2020 Intelligent Manufacturing Systems Supporting Global Research for IMS2020 Vision – Design for Environment (a.k.a. Eco-Design) Product development process that takes into accout the complete lifecycle of a product and considers environmental aspects at all stages of the manufacturing process Design for X – design for recycling; – design for disassembly; – design for energy efficiency; – design for remanufacture; – design for disposability – Green Chemistry – Green Procurement – Environmentally Conscious Manufacturing – Waste Minimization – Zero Waste 19

20. IMS 2020 Intelligent Manufacturing Systems Supporting Global Research for IMS2020 Vision Life Cycle Assessment Pollution Prevention (P2) Cleaner Production Total Cost Assessment Zero-Emissions Processes Energy Efficiency By-product Synergy Total Quality Environmental Management Factor 4, Factor 10, Factor X – X-fold increase in resource productivity 4Rs: Reduction, Reuse, Recycling and Recovery 20

21. IMS 2020 Intelligent Manufacturing Systems Supporting Global Research for IMS2020 Vision Closed Loop Lifecycle Management (CL2M) as an overall approach to product sustainability Going beyond manufacturing sustainability Include users and consumers Enabling tool for sustainable production & consumption 21

22. IMS 2020 Intelligent Manufacturing Systems Supporting Global Research for IMS2020 Vision Sustainable production & consumption – what the customer wants and what the customer needs – considering safety, health & risk aspects – change mindsets Sustainable global business models 22

23. IMS 2020 Intelligent Manufacturing Systems Supporting Global Research for IMS2020 Vision At all levels of the society Changing mindsets 23

24. IMS 2020 Intelligent Manufacturing Systems Supporting Global Research for IMS2020 Vision dimitris.kiritsis@epfl.ch 24 Thank you!